Oxy-Combustion Boiler Material Development

Foster Wheeler North America Corp A RobertsonH AgarwalM GaglianoA Seltzer

Presented At:2010 NETL CO2 Capture Technology Meeting

Pittsburgh, PASeptember 13-17, 2010

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Presentation Outline

• Foster Wheeler Background

• Project Description

– Objectives and Approach

– Project Organization and Funding

• Electric Furnace Corrosion Testing at Foster Wheeler

• Test Program

• Initial Test Findings

• Project Status and Completion Schedule

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Foster Wheeler AG — a Global Company

• Engineering and Construction Group– Designs and Constructs Processing Facilities for Many Industries

– Upstream Oil and Gas, LNG, and Gas to Liquids– Refining, Chemicals, Petrochemicals, and Power– Pharmaceuticals, Biotechnology, and Health Care

• Global Power Group – Supplies the Power and Industrial Markets

– Steam Generators and Auxiliary EquipmentPC Boilers, Fluidized Bed Boilers, MSW Boilers, HRSGs, etc

– Aftermarket ServicesCoal Mills, Control Systems, LNBs, Boiler Pressure Parts, etc

– Construction and Retrofits of Boilers, SCRs, and Scrubbers

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US DOE Cooperative Agreement DE-NT0005262Project Objectives

• Facilitate Retrofitting PC Boilers with Oxy-Combustion for CCS– Assess Corrosiveness of Oxy vs Air-Fired Flue Gas– Identify Oxy-Combustion Corrosion Mechanisms– Determine Oxy-Combustion Effects on Boiler Tube Materials

– Tubes– Tube Welds– Protective Tube Coverings

Weld OverlaysThermal Spray Coatings

• Recommend Materials for Oxy-Fired Boilers– Retrofit and New Units

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Boiler Fireside Corrosion

• Corrosion Rates Influenced by Composition and Temperature of:– Tube Materials, Flue Gas, and Deposits

• Corrosion Mechanisms Vary with Boiler Locations– Furnace Waterwalls From Reducing Gases and Incompletely Burned Coal – Superheater/Reheaters From Condensing Vapors and Deposits

• Oxy-Combustion Boiler Retrofits will Utilize Flue Gas Recycle– Maintains Air-Fired Heat Absorption and Limits Combustion Temperature– Enables Operation without Boiler De-rating or Resurfacing– Dramatically Different Combustion Atmosphere (High CO2 + H2O)– Corrosion Risks Increase Due to Increased Levels of Contaminants

– CO, H2S, SO2, SO3, HCl, etc.

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Simplified Schematic of Oxy-Fired Boiler Retrofit

Gas Rate O2 N2 CO2 H2O SO2MMlb/hr % % % % ppm Retrofit

3.6 3.0 73.4 13.8 9.1 2030 Changes3.1 2.7 8.2 67.2 20.6 3170*

*FGD at 86% Efficiency for Worst Case Boiler SO2 Levels

Nom 500 MWe Boiler Ill # 6 Flue Gas Flow Rate & Composition

Air-FiringOxy-Firing

Flue GasPreheat

Air

Oxygen

Transport

ASUO2

PreheatAir

CO2

Flue GasCooling

Air Heater StackSCRAsh

Removal

Coal Milling

PC Boiler FGD

CO2 Processing

68% Flue GasRecycle

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Project Plan / Approach

• Conduct Fire-Side CFD Analyses of Air and Oxy-Fired PC Boilers– Determine Oxy Flue Gas Recycle to Maintain Air-Fired Heat Absorption– Identify Bulk Gas Compositions and Furnace Wall Micro Climates

• Select for Electric Furnace Corrosion Testing:– Oxy and Air-Fired Gas Compositions – Waterwall and Superheater/Reheater Materials Typical of US Boilers– Deposits Representative of High, Medium, and Low Sulfur Coals

• Expose Materials to Selected Gases/Deposits in Electric Furnaces– Tests Conducted for 1000 Hrs at Waterwall & Shtr/Rhtr Temperatures – Test Gases Synthesized from Pressurized Cylinders

• Conduct Post Test Analyses to Assess Relative Corrosiveness • Recommend Materials for Oxy Retrofits & New Oxy-Fired Boilers

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Project Organization and Tasks

US DOE-NETLTimothy Fout, Project Manager

Foster Wheeler North America Corp Advisor

Task 1 Project ManagementA. Robertson H. Hack,

Director R&D

Task 2 CFD Modeling –Identification of Boiler Gas

Conditions

Task 3 Selection/Supply of Deposits

and Material Coupons

Task 4 Material Corrosion Tests

and Evaluations

A.Seltzer G. Stanko / M. Gagliano G. Stanko / M. Gagliano

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Project Costs

Budget Calendar Total DOE Portion FW Portion Period Year Costs at 80% at 20%

1 2009 $798,107 $638,486 $159,621

2 2010 $666,025 $532,820 $133,205

3 2011 $527,662 $422,130 $105,532

Totals $1,991,794 $1,593,435 $398,359

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Electric Furnace Corrosion Testing at Foster Wheeler

• Electric Furnace Corrosion Tests Frequently Conducted – Enable Screening of Materials and Study of Corrosion Mechanisms – Matls Coated with Deposits & Exposed to Gases at Elevated Temp– Furnace Holds Up to 30 Material Coupons

• Gases Synthesized from Pressurized Cylinders– Rotameters Set Flow Rates and Control Blend Ratios– Variable Temperature Humidifier Saturates Gases with Water Vapor– Test Gas Supplied to Sealed Furnaces through Heat Traced Lines

• Deposits Produced from Reagent Grade Powders• Corrosion Tests Involve Up to 1000 Hrs of Exposure Time

– Coupons Inspected & Recoated with Deposits Every 100 Hours• Coupons Undergo Post Test Metallographic Evaluations

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Typical Material Test Coupons

Rectangular Shaped Bullet Shaped1/8” T x ¾” W x 1” H ¾” Dia x 1-1/2” H

(Used for Coatings)

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Rectangular Coupons

From Weld Overlays and Tubes Butt Weld Coupon

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Typical Test Rack Coupon Arrangement

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Simplified Electric Furnace Test Schematic

Gas Humidifying Column Furnace Sealed Test Retort

Heat Tracing

Catalyst Chamber

Spent Gases to Scrubber

Mixing Chamber

Flue Gas

N2 , C

O2 , C

O, O

2

Test Specimens1000 hours

SO2 , H

2 S, HC

l

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Overview of Electric Furnace Corrosion Tests

• Boiler Materials Exposed to Synthesized Flue Gases for 1000 Hrs– 10 Waterwall Materials at: 750ºF, 875ºF and 1000ºF– 10 Superheater/Reheater Materials at: 1000ºF, 1100ºF, & 1200ºF

• Each Boiler Material Coated with 3 Different Deposits – Deposits Representative of High, Medium, & Low Sulfur Coals

– 3 Furnace Deposits and 3 Superheater/Reheater Deposits– Deposits Refreshed Every 100 Hours

• Tests Involve:– 4 Oxy- Fired and 3 Air- Fired Furnace Gas Micro Climates– 1 Oxy- Fired and 1 Air- Fired Superheater/Reheater Gas Climate

• Test Summary: 27 Furnace Tests with Total of 810 Coupons– Six Electric Tube Furnaces To Be Used

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Selection of Test Gas Conditions

• Two Nominal 500 MWe Air-Fired Boiler Retrofits Studied– Wall-Fired and Tangential-Fired Configurations Compared

– 2.5% Sulfur Illinois # 6 and 0.3% Sulfur Eagle Butte Coals Used• Ill # 6 Wall-Fired Boiler Uses 68% Flue Gas Recycle

– Heat Absorption Matched - No Changes to Tube Surfaces Needed – Flue Gas Mixed with O2 Yields 28% O2 by Volume to Boiler– Maximum Furnace Wall Heat Flux ~5% Lower than Air-Fired

• Ill #6 Wall-Fired Boiler Has Highest Furnace Wall Reducing ZonesCO H2S CO2 H2O

Air-Fired 9% 0.14% 11% 8%Oxy-Fired 20% 0.26% 48% 18%

• Ill #6 Wall-Fired Boiler Gases Selected for Corrosion Testing

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Corrosion Test Gas Compositions (Vol %)

20% CO 5% CO 2% CO 1% O2 5% CO 2% CO 1% O2 Oxy: 2% O2 Air: 3% O2

CO2 55% 67% 69% 70% CO2 13% 14% 14% CO2 69% 14%

H2O 18% 20% 20% 21% H2O 9% 9% 9% H2O 21% 9%

N2 7% 8% 8% 8% N2 73% 74% 76% N2 8% 74%

H2S 0.26% 0.07% 0.03% 0.00% H2S 0.08% 0.03% 0.00% H2S 0.00% 0.00%

SO2 0.17% 0.29% 0.30% 0.32% SO2 0.19% 0.21% 0.20% SO2 0.32% 0.20%HCl 0.02% 0.02% 0.02% 0.02% HCl 0.02% 0.02% 0.02% HCl 0.02% 0.02%Total 100% 100% 100% 100% Total 100% 100% 100% Total 100% 100%

GasWaterwall: Air-Fired Superheater/ReheaterWaterwall: Oxy-Combustion

Gas Gas

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Corrosion Test Deposit Compositions (Wt %)

Waterwalls Superheater/Reheater

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Waterwall Materials Selected for Testing

Coupon Material Description Boiler Use Composition1 Tube SA210-A1 Conventional 0.27%Carbon2 Tube SA213-T2 Conventional 1/2 Cr-1/2Mo3 Tube SA213-T11 Conventional 1-1/4Cr-1/2Mo4 Weld T11 to T11 Conventional 1-1/4Cr-1/2Mo5 Weld Overlay 309L StnStl Conventional 24Cr6 Weld Overlay Inconel 622 Conventional 21Cr-55Ni 7 Weld Overlay VDM Alloy 33 Conventional 33Cr-31Ni8 Thermal Spray IGS UTEx 5-500 Relatively New 15Cr-80Fe9 Thermal Spray IGS UTEx 5-480 Relatively New 25Cr-60Ni10 Thermal Spray IGS UTEx 5-450 Relatively New 40Cr-55Ni

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Superheater/Reheater Materials Selected for Testing

Coupon Material Description Boiler Use Composition1 Tube SA213-T22 Conventional 2-1/4Cr-1Mo2 Tube SA213-304H Conventional 18Cr-8Ni3 Tube SA213-347H Conventional 18Cr-9Ni4 Weld T22 to 304H Conventional 1-1/4 Cr to 18 Cr5 Tube SA213-T91 Newer Boilers 9Cr6 Tube NF709 Newer Boilers 20Cr-25Ni7 Tube HR3C Newer Boilers 25Cr-20Ni8 Weld Overlay Inconel 622 Conventional 21Cr-55Ni 9 Weld Overlay VDM Alloy 33 Conventional 33Cr-31Ni

10 Weld Overlay Inconel 72 Conventional 44Cr-55Ni

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Typical Waterwall Furnace Test Arrangement

750F Furnace 150

Oxy Micro-Climates 875F Furnace 2f

1000F Furnace 31000F

750F Furnace 4750F

Air Micro-Climates 875F Furnace 5

1000F Furnace 6000Deposit 1 on 10 Coupons Deposit 2 on 10 Coupons Deposit 3 on 10 Coupons

Medium Sulfur

Deposit 3 on 10 Coupons

High Sulfur

Deposit 1 on 10 Coupons Deposit 2 on 10 Coupons Deposit 3 on 10 Coupons

Low Sulfur Medium Sulfur High Sulfur

Deposit 3 on 10 Coupons

4 To Be Tested

Deposit 3 on 10 Coupons

High Sulfur

Deposit 1 on 10 Coupons Deposit 2 on 10 Coupons

3 To Be Tested

Low Sulfur Medium Sulfur

Deposit 1 on 10 Coupons Deposit 2 on 10 Coupons

Low Sulfur

Deposit 2 on 10 Coupons

Low Sulfur Medium Sulfur

Deposit 1 on 10 Coupons Deposit 3 on 10 Coupons

Low Sulfur Medium Sulfur High Sulfur

High Sulfur

Deposit 1 on 10 Coupons

Low Sulfur Medium Sulfur High Sulfur

Deposit 2 on 10 Coupons

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Waterwall Coupons After 1000 Hr 2% CO Furnace Test

Low Sulfur Deposits High Sulfur Deposits

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Cleaned A1 Coupons After 1000 Hr 2% CO Test

Air-Fired Oxy-FiredLow Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

875°F

1000°F

Low Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

1000°F

875°F

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Cleaned T2 Coupons After 1000 Hr 2% CO Test

Air-Fired Oxy-Fired

Low Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

875°F

1000°F

Low Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

875°F

1000°F

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Cleaned T11 Coupons After 1000 Hr 2% CO Test

Air-Fired Oxy-FiredLow Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

875°F

1000°F

Low Sulfur – 5% FeS Med Sulfur – 20% FeS High Sulfur – 50% FeS

750°F

875°F

1000°F

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Project Status and Completion Schedule

• Corrosion Testing:– Superheater/ReheaterTest Completed– 1% O2 Over-Fire Air Port Waterwall Test Completed– 2% CO Waterwall Test Completed– Remaining 5 and 20% CO Tests to be Completed End of March 2011

• Coupon Analyses – Analyses Underway and to be Completed End of June 2011– Oxy-Combustion Effect Varies with Material, Deposit, and Temperature

– At 1% O2 and 2% CO, 1000 Hour Waterwall Wastage Values for A1, T2, and T11 Were Mostly Lower Under Oxy-Firing

– Although Initial Waterwall Findings Encouraging More Analyses Required • Final Report to be Issued December 2011

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Acknowledgement and Disclaimer

• Project Funded by Co-operative Agreement DE-NT0005262

This presentation was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.